Cultured onyx products and methods therefor

ABSTRACT

Cultured onyx, cultured marble, and like mineral-appearing products are provided, as well as intermediates and components and methods therefor through the combination of a locally discontinuous phase comprising a synthetic organic resin portion hardened to a predetermined hardness and a visually distinguishable continuous phase comprising a synthetic organic resin portion separately hardened to the predetermined hardness with the discontinuous phase intimately distributed therein, to form shaped structures having surfaces simulative of onyx, marble, or like naturally occurring mineral in appearance, which surfaces are uniformly polishable in phase undifferentiated relation.

This application is a division of application Ser. No. 146,749 filed May5, 1980 now U.S. Pat. No. 4,433,070.

This invention has to do with products simulative in appearance to thenaturally occurring semi-precious silicas known as onyx, or to likeminerals such as marble. More particularly, the invention is concernedwith novel materials and methods and mineral simulative productsresulting therefrom, characterized by enhanced fidelity to naturalmaterials in appearance, in improved resistance to deterioration intheir expected use environment, reduced weight for lower cost shipping,and in versatility of design configuration. Moreover the presentmaterials, methods and products are achieved at significant reductionsin manufacturing costs by virtue of the elimination of variousmanufacturing steps heretofore thought necessary in the cultured onyxand cultured marble industry. In the ensuing description, cultured onyxwill be primarily referred to as an ideal illustrative embodiment of thepractice of the invention.

A large market exists for tubs, pullmans, tile, tub enclosures, plaques,sculptures, and other shaped products having the uniquely attractive,nearly nacreous layered translucent depth of onyx, an optical effectheightened by the presence of subtly or strongly contrasting, diffusestriations of visually differeniatable localized zones of concentrationof contrastant having indistinct mergence with the surrounding matrix inthree dimensions. In general, this market has been supplied withproducts based on a polyester resin matrix extended and opticallymodified with a filler comprising tiny glass particles, referred to asfrit.

PRIOR ART

In U.S. Pat. No. 3,396,067 to K. A. Schafer the simulation of naturallyoccurring onyx in a wide variety of useful products is taught to beachievable by blending polyester resins filled with one or anotherfillers, e.g. silicas and more particularly glass frit in a specificmanner to interdistribute essentially alike polyester phases andthereafter simultaneously curing all the polyester to hardness with onephase frozen in another. The disadvantages of the technique taughtinclude obtention of a nonpolishable surface and excess weight sinceglass is more than twice as heavy as polyester resin and so hardrelative to the polyester that surface polishing produces a multiplicityof discrete islands too small to really be seen and too numerous tocount but which in the aggregate appear as a surface dullness whichincreases with polishing rather than diminishing. Thus those in the arthaving only the Schafer process and product have resorted to gel coats,surface coverings of clear resin, which are polished appearing, toconceal the true surface and thus beautify the product. Unfortunately,this expedient brings its own problems, since gel coats may be rubbedthrough by too vigorous cleaning, which may occur in a washbasin, forexample. Too they are typically water vapor pervious, and over time, inuse, they permit water seepage into the underlying structure which ismanifested by a separation of the gel coat from the substrate, and theresultant appearance of an air pocket or bubble behind the gel coatwhich is disruptive of the light reflection and spoils the productaesthetics.

SUMMARY OF THE INVENTION

It is therefore a major objective of the present invention to providenovel cultured mineral products, having the surface appearance of, e.g.cultured onyx and cultured marble. It is another objective to providesuch products in the form of shaped articles having: the requisitesurface appearance; lighter weight for reduced shipping costs; toughersurfaces against in-use degradation; uniform polishability deriving fromchemical and physical property homogeneity at the surface; freedom fromcostly gel coats which are likely to wear or lift off from water vaporpermeation; ease of shape forming into conventional as well asnonconventional, artistic and aesthetic products; increased variety ofvisual effects through limitless variation in color, size, uniformity ofsize, concentration, distribution, and patterning of the filler,colorants, and matrix relative one to the other, as compared withpreviously known cultured mineral products, such as cultured onyx. It isa further objective to provide method for the preparation of culturedonyx and like products which is economical, productive of enhancedaesthetic effect, and free of requirements for gel coat cover up ofsurface imperfections inherent in prior art methods. It is a particularobject to provide product comprised of individually hardened portions ofa chemically alike resins whereby surface imperfections deriving fromdifferent hardness materials at the product surface are avoided. Anotherhighly importnt object is to provide cultured marble or onyx simulativeshaped articles and products such as tubs, tub enclosures, lavabos,pullmans, basins and vases, fixtures, fountains and the like which arefree of internal hygroscopicity inducing agents such as glass and whichthereby are impervious to humid environments or water contact and ableto be free of gel coats whereby unsightly lifting of film at the productsurface is avoided and the aesthetic and practical use life of theproduct greatly extended. Still other objectives include having likedensity components against gravity separation in lay-up, deriving thematrix and filler portions from the same resin, preferably a polyesterresin, with each portion being hardened in a separate step, and theprovision of a universal filler system comprising neutral color resinparticles triturated to the proper size range and used with individualcoloration in the matrix resin which is only then cured with the fillercooperating with the the colorant, or more broadly the contrastant,since apparently similar colors of matrix and filler are distinguishableas optically varying when the particles of filler are distributivelydisposed in locally concentrated relation in the surrounding, productshape defining resin. Further objectives include providing methods ofmolding shaped products, methods of preparing intermediates, andtechniques for obtaining the optimum in cultured onyx and like mineralproduct appearance with maximum beneficial physical and chemicalproperties, and the provision of products having water receivingreceptacles and conduit therein, and withal the appearance of onyx,marble and like naturally occurring materials, but of infinitelyvariable shape and utility.

These and other objects of the invention to become apparent hereinafter,are realized in accordance with the invention which provides a shapedstructure having a polishable cultured onyx, cultured marble, or likemineral-appearing surface of predetermined hardness, the structurecomprising a locally discontinuous phase comprising a synthetic organicresin portion hardened to the predetermined hardness and a visuallydistinguishable continuous phase comprising a synthetic organic resinportion separately hardened to the predetermined hardness with thediscontinuous phase intimately distributed therein, whereby thestructure surface is simulative of onyx or like mineral appearance anduniformly polishable in phase undifferentiated relation.

The locally discontinuous resin portion typically comprises particles ofresin hardened to the predetermined hardness prior to intimatecombination with the continuous resin portion and which are less thanabout 50 U.S. mesh in mean average particle size diameter. Thediscontinuous resin portion particles preferably comprise polyesterresin.

The continuous resin portion also preferably comprises polyester resinand embeds the discontinuous portion in local discontinuity anddistribution defining relation.

The locally discontinuous resin portion particles of hardened resin mayhave a mean average particle size diameter less than about 80 U.S. mesh.

Typically, the discontinuous resin portion particles comprise from about5% to 55% of the weight of the structure.

In particularly preferred embodiments, the continuous resin portion andthe discontinuous portion are each polymers of the same monomer, e.g.each polyester resin.

The structure typically also includes a colorant distinguishable withinthe continuous phase, e.g. dispersed nonuniformly in continuous phase.Further the discontinuous phase is typically particulate, uniformlydistributed in the continuous phase, and the structure also includes acolorant nonuniformly dispersed in the continuous phase.

The invention contemplates provision of a moldable mixture hardenableinto the foregoing product, i.e., a resinous mass for the production ofcultured onyx, cultured marble, or like mineral product comprisingvisually distinguishable portions of synthetic organic resin, includinga first, major weight portion defining a continuous, moldable andhardenable resin matrix, a second, minor weight portion defining aparticulate, pre-hardened resin filler of less than about 50 U.S. meshin mean average particle diameter, the second resin portion particleshaving discontinuous distribution in the first resin portion matrix, anda colorant visually distinguishably marking the product with randomlylocalized zones of distributed filler concentration, the zones havingindistinct mergence with the surrounding matrix in three dimensionsafter mold-shaping and hardening of the matrix portion simulatately ofthe surface appearance of onyx, cultured marble, or like mineral.

The second resin portion typically constitutes from 25% to 50% by weightof the resinous mass, and the first portion or matrix is hardenable withthe filler in situ to the hardness of the filler to have both filler andmatrix portions which may be polymers of the same monomer substantiallyequally wear resistant to polishing on the product surface.

The invention further contemplates provision of an intermediate forinclusion in the above moldable resinous masses, as well as in themineral like final product. This intermediate according to the inventioncomprises resinous particles for the production of cultured onyx,cultured marble, or like mineral product by combination in effectiveproportion with visually distinguishable synthetic organic resin, theresinous particles comprising polyhedral chips of a relatively large,hardened mass of synthetic organic resin, the particles being usefulwithout further hardening, preferably comprised of polyester, and havinga mean average particle size diameter of less than about 50 U.S. mesh.The resinous particles after being chipped from the relatively largemass e.g. under low temperature conditions, may have a colorant added,where the large mass is not of a visually distinctive color tonerelative to the tone of the intended matrix resin portion, e.g. byincorporation of colorant for visually distinguishing the particlesrelative to the synthetic organic resin matrix.

The combining of the foregoing particulate filler with the hardenablematrix, into the blend described above produces after molding to adesired shape a shaped cultured onyx, cultured marble, or likemineral-appearing product having a predetermined surface hardness andcomprising first and second, visually distinguishable portions ofsynthetic organic resin, including a first, major weight portiondefining a continuous, molded post-hardened resin matrix, a second,minor weight portion defining a particulate, pre-hardened resin fillerof less than about 50 U.S. mesh in mean average particle diameter, thesecond resin portion particles comprising polyhedral chips of arelatively large hardened resin mass and having discontinuousdistribution in the first resin portion matrix in a manner visuallymarking the product with distributed filler having indistinct mergencewith the surrounding matrix in three dimensions simulatively of theappearance of onyx, cultured marble, or like mineral. As in previousembodiments, a colorant may be nonuniformly distributed in the resinmatrix to enhance the simulative effect, the locally discontinuous resinportion chips may be colored with added colorant, comprise polyesterresin, and be less than about 80 U.S. mesh in mean average particle sizediameter; the continuous resin portion may also comprise polyesterresin, e.g. the continuous and discontinuous portions may be polymers ofthe same monomer, and embed the discontinuous portion and colorant inlocal discontinuity and distribution defining relation; and thediscontinuous resin portion particle chips typically comprise from about25% to 55% of the weight of the product, and may be artificiallycolored.

In one highly useful form of the invention, water receptacles, such aspullmans, lavatories, water closets, tubs, and other receptacleapparatus such as faucets, faucet handles and spigots, the shapedproduct includes means defining a passage within the product, for thepassage of water or other fluid, for receiving bolts, screws and otherfastening hardware, or for defining a wall aperture for water flow orinsertion of fixtures.

For this purpose the shaped product passage defining means in faucet andpiping applications will typically include a separately formed conduitmember, e.g. brass tubing, the product further defining means tomaintain the member within the passage, such as end fittings adapted tobe sweated onto the brass tubing and to threadedly engage aerators andmounting bosses in product installations.

The invention also contemplates method of manufacturing a cultured onyx,cultured marble, or like mineral-appearing surface structure, whichincludes combining with a first hardenable synthetic organic resinportion a second pre-hardened particulate synthetic organic resinportion, the first resin portion being hardenable to a like hardness tothe second resin portion, hardening the first resin portion with thesecond resin portion distributively disposed in situ therein to the likehardness in the desired form of the structure. The method further mayinclude adding powdered, or liquid colorant, hardening the second resinportion in a relatively large mass and triturating the mass, afterfreezing to aid crushing, if desired, to obtain the desired amount ofthe desired size particulate.

It is signal feature of the present invention and method that by virtueof the like hardnesses of the resin portion phases it is possible topolish the surface of the structure to a uniform gloss, without use ofan overlayer of gelling resin, i.e. in gel coat free relation.

With further reference to the present method, it includes also hardeninga polyester resin as the second resin portion, triturating the hardenedresin portion to a particulate mass having an average mean particle sizediameter of less than about 50 U.S. mesh and combining the second resinportion with a first resin portion comprising hardenable polyesterresin; proportioning the first and second resin portions so that thesaid second resin portion constitutes from 25% to 50% of the structureby weight; depositing the combined resin portions into astructure-defining form prior to hardening of the first resin portion;adding locally concentrated marblizing colorant to the mixed portionsand gently swirling or stirring to combine without mixing to define theonyx or marble simulative striations; and thereafter hardening the firstresin portion with the prehardened second resin portion distributivelydisposed therein; maintaining a passage within the combined resinsduring hardening of the first resin into a structure; and disposing apreformed, e.g. passage-defining element in the combined resins prior tohardening of the first resin to maintain a passage therewithin.

Alternatively stated, the invention contemplates the method ofmanufacturing a cultured onyx, cultured marble or like mineral-appearingstructure, which includes confining in a forming zone previouslyhardened, particulate polyester resin and a visually distinguishable,liquid, hardenable polyester resin in distributively commingled relationand colorant in such relative proportions and patterns as to provide anonyx, marble or other mineral simulative surface appearance, andhardening the hardenable portion while confining the resin within thezone, and the product made by the method.

Further there is contemplated in a cultured onyx, cultured marble orlike mineral-appearing product comprising a hardened resin matrix and aparticulate filler distributed therein in visually varying relation, theimprovement in which the filler comprises a separately hardened portionof a chemically like resin to the matrix resin, whereby the surface ofthe product is visually varied and compositionally uniform.

And still further contemplated is a cultured onyx, cultured marble, orlike mineral-appearing structure filler comprising a synthetic organicresin portion, e.g. of polyester, hardened to a hardness desired in afinal structure, and triturated to particulate form having a meanaverage particle size of less than 50 mesh, and having an added colorantif desired, for use in such product manufacture.

There is also provided the method of manufacturing resinous particulatefiller, including forming a body of hardened resin, freezing the body,and thereafter locally impacting the body in body-fracturing relation,further reducing the fracture product by impact at below roomtemperature, and using nitrogen or carbon dioxide for either or bothfracture and further reduction operations, as the source of coldtherefor.

BRIEF DESCRIPTION OF THE DRAWING

The invention will be further described as to an illustrative embodimentthereof in conjunction with the attached drawing, in which:

FIG. 1 is a perspective view of a shaped product, namely a faucetproduced in accordance with the methods of the invention, using thecompositions of the invention;

FIG. 2 is a view in horizontal section thereof; and

FIG. 3 is a view in vertical section of a faucet handle shaped productaccording to the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention uses a resin portion as filler. The resin filleris prepared by hardening a heat or catalytically curable liquid resin,such as polyester, or other resin as described below, in bulk to form asolid body of hardened resin. The degree of hardening is not narrowlycritical, with typical resin bodies being not friable but trituratableby application of grinding or abrading force. Thus a body of hardenedresin is triturated to a fine powder comprised of discrete particles ofgenerally polygonal shape, by impacting at high centrifugal speedagainst circularly fixed teeth under temperature conditions conducive toembrittlement of the resin body so as to facilitate erosion of the bodyand generation of particulate. Crushing of the resin body after freezingis effective, with the resultant lumps being further refined by highspeed impact with appropriately arranged teeth, also under loweredtemperature conditions where resin gumming may occur. A grind to atleast 50 U.S. mesh mean average particle size diameter is usuallyrequired for obtaining a cultured onyx product, although other mineralshaving coarser, even grainy striations may be made with coarserparticulate, and grinding will not have to be so fine. A mean averageparticle size of 80 U.S. and below is preferred for optimum subtlety oftransition from accent to background in cultured onyx. Typically thehardened resin body is coarsely divided and the coarse pieces impactedagainst teeth until a particulate of the desired size distribution isrealized.

The particulate filler may be the color of the resin body which in apolyester resin tends to be a water white to gray in the absence ofadded colorant. A colorant, i.e. a material imparting a color valueother than the naturally occurring color, may be added to the resin,e.g. before hardening, for example an organic or inorganic dye and/orpigment, liquid or solid powder, may be added to a slurry of thepolygonal chips in uncured resin or other vehicle prior to addition ofthe particulate to the matrix resin. Advantageously, a masterbatch ofchips may be prepared and specific colorants added as need be from timeto time for product production purposes, thus to minimize inventory ofcolors. The use of reactive color formers on the particulate is alsopractical, the color being developed in situ in the product. The colormay be any tone including deepened or lightened aspects of the eventualmatrix color. In this connection, it is the presence of visualdistinguishability through the presence of a contrast between the phasesof the product that is important, not specific color contrasts. Thepolyester resins for example exhibit contrast between commingled phasesregardless of a colorant as an additional contrastant.

The hardened filler is then mixed with the matrix material, suitably afurther portion of the filler resin. Colorant to form localizedconcentrations of high contrast, e.g. striations, bursts, veins, whorls,umbras and the like, typical of onyx and marble is added. The mix iscontrollably agitated or not as desired to achieve the nonuniform,locally randomized, concentration pattern of distribution of colorant inthe uniformly comixed filler and matrix. Swirling, agitating, addingfrom single or multiple points in thick or thin streams all have theireffect on the final pattern. It is preferable to slowly combine a firstmix of a given background color of liquid, nonhardened matrix and thehardened filler particulate with a second mix of another backgroundcolor of liquid, nonhardened matrix resin and the hardened filler and tocombine these different background color mixes with pigment or otherpattern forming colorant, with careful definition of distribution, andthen to add the combined mixes and colorant to the mold to be used toshape the product structure using more or less percentage of particulatefiller to vary the viscosity of the combined mixes for application tothe form and to determine the apparent concentration of pattern in thefinal product desired, more mixing reducing colorant concentration andless mixing maintaining an initial pattern of distribution. Thesubstantially equivalent specific gravities of the filler and matrix inthe invention preferred compositions give a high degree of control overdistribution pattern not available where the filler for example is farheavier than the matrix, as in prior art systems.

The relative quantities of filler and matrix for achieving a culturedonyx appearance is between about 5% and 55% of filler on the totalweight of the product, with the balance being matrix, colorant and anyspecific additives employed. Typically, colorant is added at the rate ofabout 0.1 to 1.5% of the total weight of the product. The term "product"herein refers to the combination of two resin phases, without regard tocolorants, contrastants, extenders, and nonresin components present in afinal shaped structure. This ratio again is for achieving the bestappearing cultured onyx product, other mineral simulations can use otherratios, e.g. from as little as 0.5% filler to as much as 75% filler byweight, based on the weight of the product, the matrix converselycomprising from 99.5% to as little as 25% by weight of the product.

After the combined resins are placed in a suitable mold, the matrixresin is cured, by heat and/or catalysis with the filler resin in situtherein. A signal feature of the present invention is the cohardening ofthe matrix to the hardness of the filler or approximately so, to adegree affording a polishability to the filler and matrix phases at theproduct surface which is uniform across the phases. The result is thatupon polishing, by sanding, buffing and/or light grinding, both phaseswear, or do not wear, but do so evenly and uniformly, so that islands ofrelatively harder filler do not protrude, as happens with glass fritfillers, as polishing progresses. In the present products, the fillerand matrix wear at the same rate, i.e. without phase differentiationwhere the filler and matrix are hardened to the same degree.

Molding of the combined resin phases is acomplished simultaneously withthe hardening of the matrix about the prehardened filler. The finalshape of the product is determined by the mold as in other moldingprocesses.

The mold may typically define a tub or wash basin, or countertop or thelike. Advantageously with the present method and products, shapedarticles of increased value relative to their resin content can beformed reliable and easily. For example, faucets and handles foroperating water control valves can be readily molded of the presentmoldable combination of hardened and unhardened resin.

With reference now to the accompanying drawing, a faucet is depicted inFIGS. 1 and 2. The faucet F is shown to comprise a neck portion 16 and abase 24, the base being centrally recessed to receive a brass fitting 22with the fitting annular shoulder 22a being embedded within the moldedfaucet for security of fit. A conventional threaded conduit 28 extendingfrom household plumbing (not otherwise shown) is threaded into thefaucet fitting 22 at 26. A preformed element in the form of a conduit 20of plastic or brass extends through the faucet neck 16 defining a waterpassage 18 therethrough. The conduit 20 is sweated to the fitting 22 atone end and to the fitting 32 at the faucet nozzle 30. Nozzle fitting 32is suitably molded in place and interiorly threaded at 36 to receive aconventional aerator.

The received preformed element can be any structure which lends aparticular utility to the final molded product. In a faucet handle, forexample, and with particular reference to FIG. 3, the knob 10 definesthe handle and is provided with a central top recess 12 which receivesfor subsequent concealment under a hot/cold tab, a valve stem 14 throughbushing 15 which is fitted in the central bore 17 of the handle.

Resins useful herein for formation of one or both of the two phases,i.e. the locally discontinuous phase and/or the continuous phase arethose resins which harden to useful rigidities for use as structuralproducts. First among such resins for onyx simulation is the polyesterresin. Polyester resins are well known and amply described for examplein the 1979-1980 Modern Plastics Encyclopedia. Such resins are thereaction product of a dibasic acid and a glycol, e.g. phthalicanhydride, isophthalic acid and adipic acid with one or more ofpropylene glycol, ethylene glycol, diethylene glycol and dipropyleneglycol. Crosslinking monomers used include styrene, vinyl toluene,methyl methylmethacrylate, methyl styrene, and diallyl phthalate.Inhibitors such as quinone, hydroquinone and butyl catechol may be used.Typical catalysts for the reaction are free radical precursors, e.g. theperoxides which decompose at elevated or ambient temperatures, e.g.methyl ethyl ketone peroxide, cyclohexanone peroxide, and benzoylperoxide, or cumene hydropentoxide, t-butyl perbenzoate and peroctoate.Resins of less intrinsic clarity will be useful where the ultimate intranslucency is not required. Accordingly such thermosetting (includingroom temperature cure) resins as allyls, ureas, phenolics, polyimides,epoxy, and polyurethanes, may be used in particular cases.

It is particularly preferred herein to employ different portions of thesame resin as the raw material for the two distinct phases, one to behardened and triturated, then distributed in the other portion,whereupon the second portion is the hardened, giving a two phasecomposition with the difference being not chemical or physical butrelated to form (continuous or discontinuous) and derived from the timeof cure or hardening.

EXAMPLE

A polyester resin was hardened by the application of moderatetemperature, ca. 175 degrees for a period of 60 minutes in a simplerectangular mold to provide a body of hardened resin weighing about 5pounds. The body was frozen instantly in liquid nitrogen and crushed inan impact mill into pieces approximately 1/4 by 1/4 inches on a side,and these pieces fed centrifugally against a series of teeth in acircular path to reduce the pieces in after sufficient passes topolyhedral chips of nonsymmetrical shape and of a mean average particlesize of 80 U.S. mesh screen. The particles were combined with a colorpigment in a quantity of liquid uncured resin of the same type. Afurther portion of this polyester resin was combined with particulate,and without the addition of any colorant. These mixtures were thencombined to achieve a ratio of 48% particulate by weight relative to thenonhardened resin. Colorant in the form of liquid pigment wasdistributively added to the combined resins, and a swirl patternestablished. The combined resin portions and swirled colorant thereinwere cast in a faucet mold and the the resin matrix as had been theparticulate to achieve like hardness. The preformed element, e.g. theconduit and fittings is inserted in the mold in suitably supportedrelation prior to cure if it is desired to have the element embedded.The part was removed from the mold and lightly buffed to a high gloss.The onyx like translucent striation and veining was striking, both indepth and diffusion below the article surface and in its feathering offinto indistinct mergence with the surrounding matrix beyond its locus ofconcentration, the interposition of solid filler through the matrixliquid serving to give the localized concentrations of striationdefining colorant an imperfection of line and edge definition whichheightens the comparability to naturally occurring striated, colormarked minerals.

Water vapor exposure did not affect the product surface on testing. Theabsence of a gel coat on the product is to be noted. Heretofore highgloss was dependent on application of a glossy film former onto themolded product, because buffing highlighted the harder filler as iteroded the softer matrix. Wih the present product, however, the fillerand matrix phases are of substantially coequal hardness. The problems offilm lift off and poor abrasion resistance, formerly tolerated becauseof the need for a high gloss on the cultured onyx or cultured marbleproduct, have been obviated.

Accordingly, the invention provides a novel product overcoming thedisadvantages of previous products and opening new opportunities for themanufacture of highly attractive cultured onyx and marble products, suchas the traditional tubs, pullmans, basins, water closets, lavabos, andadditionally fountains, sculptures, tiles, wall decorations, faucets andhandles, soap dishes and statuary.

We claim:
 1. The method of manufacturing a cultured onyx, culturedmarble, or like mineral-appearing surface structure which includescombining with a first hardenable synthetic organic resin portion, asecond visually distinguishable pre-hardened particulate syntheticorganic resin portion, said first resin portion being hardenable to alike hardness to said second resin portion, hardening said first resinportion with said second resin portion distributively disposed in situtherein to said like hardness in the desired form of said structure. 2.The method according to claim 1, including also, adding colorant,hardening said second resin portion and triturating to the desired sizeparticulate.
 3. The method according to claim 2, including alsopolishing the surface of the structure to a gloss in gel coat freerelation.
 4. The method according to claim 2, including also hardening apolyester resin as said second resin portion, triturating the hardenedresin portion to a particulate mass having an average mean particulatesize diameter of less than about 50 U.S. mesh and combining said secondresin portion with a first resin portion comprising hardenable polyesterresin.
 5. The method according to claim 1, including also proportioningthe first and second resin portions so that the said second resinportion constitutes from 25% to 50% of said structure by weight.
 6. Themethod according to claim 1, including also depositing said combinedresin portions into a structure-defining form prior to hardening of saidfirst resin portion, and thereafter hardening said first resin portionwith said prehardened second resin portion distributively disposedtherein.
 7. The method according to claim 6, including also maintaininga passage within said combined resins during hardening of said firstresin into a structure.
 8. The method according to claim 7, includingalso disposing a preformed passage-defining element in said combinedresins prior to hardening of said first resin to maintain a passagetherewithin.
 9. The method according to claim 6, including alsodisposing a preformed element in said combined resins prior to hardeningof said first resin.
 10. The method of manufacturing a cultured onyx,cultured marble or like mineral-appearing structure, which includesconfining in a forming zone a previously hardened, particulate polyesterresin, a colorant, and a visually distinguishable, liquid, hardenablepolyester resin in distributively commingled relation and in suchrelative proportions as to provide an onyx, marble or other mineralsimulative surface appearance, and hardening the hardenable portionwhile confining the resin within said zone.
 11. The product made by themethod of claim 10.